Adjustably Interconnectable Formwork

ABSTRACT

An adjustable connector system for stay-in place formwork has a male adjustable connector end that can be inserted into a corresponding female adjustable connector end at variable positions. Using adjustable connector ends in assembling a formwork system increases accuracy by facilitating on-site adjustability of the length and/or diameter measurements of the system. The stay-in-place formwork can be used to create building surfaces, including ceiling panels, siding and walls, and can be used for forming concrete structures, such as walls and sumps.

TECHNICAL FIELD

This invention relates to stay-in-place formwork for creating building surfaces such as ceiling panels, siding and walls, and for forming concrete structures.

CROSS REFERENCE TO RELATED APPLICATIONS

None.

GOVERNMENT SUPPORT

None.

BACKGROUND

Concrete structures are formed by pouring concrete into a particular space, usually in the presence of steel reinforcing bars (re-bars) to add strength to the structure. Wall elements known as concrete forms can be used to keep the concrete contained so that the poured concrete solidifies in the location and shape desired.

Various designs and uses of concrete forms are known. For example, modular formwork elements and assemblies are described in U.S. Pat. Nos. 5,740,648, 6,219,984 and 6,694,692 to Piccone, which are incorporated herein by reference.

Formwork elements are prefabricated and then pieced together on-site. Concrete forms typically have discrete inner and outer wall panels to create inner and outer wall surfaces. The inner and outer wall panels can be held in place by cross-panels (or reinforcing panels) that span the inner and outer wall panels, creating a formwork assembly having a series of vertically extending cells into which concrete may be poured and left to harden. The inner and outer wall panels can be further reinforced by the addition of bracing panels, which can be connected to an inner or outer wall and/or a cross-panel at 45 degree angles. The cross-panels and bracing panels are usually formed with apertures so that re-bars and poured concrete can pass through the apertures to connect adjacent cells and form a continuous reinforced concrete structure.

Known concrete forms of this nature are often made from polyvinyl chloride (PVC). Manufacturing tolerance variations and expansions and/or contractions of PVC and other materials due to temperature changes can give rise to variances between the required length or diameter of a structure and the measured and/or manufactured formwork panels.

Prefabricated ceiling panels and siding panels can be subject to similar manufacturing tolerance variations and expansion and/or contraction.

There exists a need for a way to make on-site adjustments to the length of prefabricated formwork panels so that the resulting formwork structure is assembled to its correct dimensions.

SUMMARY OF INVENTION

An apparatus of building components has a first component with a female adjustable connection and a second component with a male adjustable connection, such that the male adjustable connection is lockably insertable into the female adjustable connection in a plurality of positions thereby varying the length of the combination of first and second components.

A method of installing a building structure involves inserting a first male adjustable connection end of a first building component into a first female adjustable connection end of a second building component. The first male and female adjustable connection ends are adjustable with respect to each other to lockably adjust a distance that the first male adjustable connection end is inserted into the first female adjustable connection end to effectively adjust the length of the combination of the first and second building components.

BRIEF DESCRIPTION OF DRAWINGS

In figures which illustrate non-limiting embodiments of the invention:

FIG. 1 is a plan view of an embodiment of the invention having three separated formwork pieces, namely two female adjustable connectors and one male adjustable connector;

FIG. 2 is a plan view of the embodiment of FIG. 1 with the three formwork pieces connected together;

FIG. 3 is a plan view of an embodiment of the invention with adjustable components connected to form a cell connected to other formwork elements;

FIG. 4 is a plan view of an embodiment of the invention having single adjustable connections at each of the inner and outer walls of an otherwise fixed length formwork system;

FIG. 5 is a plan view of the embodiment of FIG. 4 incorporated into a wall formwork structure;

FIG. 6 is a plan view of an embodiment of the invention forming a cylindrical formwork structure;

FIG. 7 is a plan view of a portion of the embodiment of FIG. 6;

FIG. 8 is a plan view of a portion of the embodiment of FIG. 7;

FIG. 9 is a plan view of a formwork panel according to an embodiment of the invention having two adjustable female connection ends and one male adjustable connection end;

FIG. 10 is a plan view of a wall incorporating the formwork panel of FIG. 9;

FIG. 11 is a plan view of a formwork panel according to an embodiment of the invention having two adjustable female connection ends and one male adjustable connection end;

FIG. 12 is a plan view of a formwork panel according to an embodiment of the invention having an adjustable female connection end and an male adjustable connection end;

FIG. 13 is a plan view of an embodiment of the invention having three separated formwork pieces, namely two female adjustable connectors and one male adjustable connector;

FIG. 14 is a plan view of the embodiment of FIG. 13 with the three formwork pieces connected together;

FIG. 15 is a plan view of an embodiment of the invention having two separated formwork pieces, namely an adjustable female connector and an adjustable male connector;

FIG. 16 is a plan view of the embodiment of FIG. 15 with the two formwork pieces connected together; and

FIG. 17 is a plan view of an embodiment of the invention having three formwork pieces connected together along with a spacer.

DESCRIPTION

Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

With reference to FIGS. 1 and 2, embodiment 10 has a female adjustable connector 20 and a female adjustable connector 22, each of which have a female adjustable connector 26 and 28, and a fixed female connection end 30 and 32. Each of the female adjustable connection ends 26 and 28 are comprised of a series of ribs 34 and gaps 36 formed between ribs 34. Double-ended male adjustable connector 24 at male adjustable connection ends 40 and 42 is configured to be inserted in female adjustable connection ends 26 and 28 respectively. Double-ended male adjustable connector 24 is similarly comprised of a series of ribs 34 interspaced by gaps 36, which correspond to the ribs 34 and gaps 36 of the female connection ends 26 and 28. The combination of the female adjustable connection ends 26 and 28 on connectors 20 and 22 when combined with double-ended male adjustable connector 24, is such that the spacing between female connector 20 and female connector 22 is adjustable depending upon how much of male connection ends 40 and 42 are inserted into female adjustable connection ends 26 and 28.

In FIG. 2, double-ended male adjustable connector 24 is inserted at male adjustable connection end 14 into female connection end 26 with two ribs of female connection end 26 not utilized, and with three ribs of female connection end 28 not utilized by the male connector 24. As shown in FIG. 2, in this particular arrangement, there is a gap of distance 44 between female connector 20 and female connector 22 of the space equaling the distance from the beginning of one rib to the end of the fourth rib 34 on double-ended male connector 24. If double-ended male connector 24 were inserted at a different length into one or both sides of the female connection ends 26 and 28, the distance 44 separating female connectors 20 and 22 would change accordingly.

Embodiment 10, through fixed female connection ends 30 and 32, can be connected to known fixed-length modular formwork panels, such as those described in U.S. Pat. No. 5,740,648 to Piccone, to add an adjustable length variation segment.

With reference to FIG. 3, embodiment 50 is a segment of formwork elements for forming a segment of wall. Cross-panel or reinforcing panel element 52 has adjustable female connection ends 54 and 56. Reinforcing panel 58 has adjustable female connection ends 60 and 62. Reinforcing panels 52 and 58 are separated by male double-ended connection ends 64 and 66 respectively at a separation distance 68.

Reinforcing formwork members 70 and 72 are shown with truncated portions representing indeterminate length at points 74. Reinforcing panel member 70 has a female fixed connection end 80 which snaps into male connection fixed end 76 of reinforcing panel 52. Similarly, reinforcing panel 58 has a female fixed connection end 78 which is snapped into by male connection end 82 of reinforcing panel 72. Male connection end 84 of reinforcing panel 52 is snapped into female can fixed connection end 88 of reinforcing panel 70. Male fixed connection end 90 of reinforcing panel 72 is snapped into female connection end 86 of reinforcing panel 58. The resulting wall structure creates an inside wall surface 92 and an outside wall surface 94. The space between the inside wall surface 92 and the outside wall 94 forms a cavity 96, which is suitable for receiving concrete/cement and/or insulation, as required.

With reference to FIG. 4, embodiment 100 is an interconnected closed-loop chain of formwork elements 102, 104, 106, 108, 118, 124, 136 and 142, which together create cell cavity 164.

Connector 102 has an adjustably interconnectable male end 110 for slideably and lockably engaging an adjustably interconnectable female end 112 of connector 106. Connector 102 has a fixed interconnectable female end 116 for slideably and lockably engaging a male connection end 162 of connector 118.

Connector 106 has a fixed interconnectable female end 120 for engaging a male end 126 of formwork member 124. Connector 106 has a fixed interconnectable male end 122 for engaging with a formwork element not shown in FIG. 4, but shown in FIG. 5.

FIG. 5 illustrates embodiment 170 which incorporates embodiment 100 into a larger wall formwork structure, including the formation of cell cavity 188. Wall connector panel 172 is connected to connector 106, cross-panel 180 and wall panel 176 via fixed connections. Wall panel 174 is connected to connector 108, cross-panel 180 and wall panel 178 via fixed connections. Cross-panel 180 is shown with fixed female connectors ends 182 which could be connected to other panels as desired, such as connecting to a bracing panel that could be added at a 45 degree angle and connected to wall panel 172, etc.

Wall panel 184 is connected to connector 118 and wall panel 186 is connected to connector 142 via fixed connection. Wall panels 176, 178, 184 and 186 are shown to be of indeterminate length at points 74.

With reference to FIG. 6, embodiment 190 shows formwork elements arranged to create a cylindrical formwork column. The connection of formwork elements results in an outer wall 192 of circular cross-section, and inner wall 194 of circular cross-section, having reinforcing framework elements 196. In embodiment 190, there is a fixed female connection end 200. Cement can be poured into the cavities 202 created by the combination of formwork elements. Portion 210 of embodiment 190 is shown in FIG. 7 in further detail.

With reference to FIG. 7, column portion 210 comprises a connector system 214 shown in even further detail in FIG. 8. The formwork elements in FIG. 7 together create outer wall 192 and inner wall 194. Reinforcing element members 196 help the structure retain rigidity and shape. Connector 198 adjustably connects formwork elements to enable more exact shape than if the adjustable nature of the connection were not present.

As shown in FIG. 8, connector 198 comprises female adjustable connection ends 218 and 220 and a fixed female connection end 222. It is understood that in other embodiments, one or all of the connection ends could be adjustable.

With reference to FIG. 9, embodiment 224 is a formwork element having a female connection end 226 which is seamlessly integrated at point 228 such that an outer wall surface 234 can be created smoothly from the flat section through to the connection section. Adjustable female connection end 230 is provided to allow adjustable connection to reinforcing members. Adjustable male connection end 232 is disposed inwardly from outer wall surface 234 to be offset at elbow 236 by a distance which corresponds to the distance to insert into a female adjustable connection end to create a flat outer wall surface when the male end is fully inserted into the female end, for example as shown at connection 252 in FIG. 10.

With reference to FIG. 10, embodiment 240 shows formwork element 224 incorporated into a wall structure having outer wall surface 234 and inner wall surface 248.

Prefabricated seam-filling segments can correspond to the shape and distance of a male adjustable connector sticking out of a female adjustable connector, whether that distance relates to 1, 2, 3, 4 or more ribs, such that the outer wall surface can be easily and immediately filled into to a flat surface even when the male and female adjustable connection ends 232 and 226 are not completely inserted into one another in a manner that might otherwise leave an indented gap in the outer wall surface 234. Seam filling segment 238 is an example of such a segment, in this case relating to an indentation gap 242 created when two ribs of the male adjustable connection end 232 stick out of the corresponding female adjustable connection end 226.

Adjustable female connection ends 230 are connected to reinforcing members 244 and 246 respectively, forming cell cavity 250. In one instance, a male adjustable connection end of reinforcing member 246 is not inserted completely into the corresponding female adjustable connection end such that a gap 248 appears within the female adjustable connection end. As the male and female adjustable connection ends have a multiplicity of ribs, reinforcing panel 246 is firmly held in position by the adjustable connection irrespective of the gap 248 due to the rib(s) that remain in contact.

Embodiment 260 in FIG. 11 is a panel element having a smooth male connection end 262 and a smooth female connection end 264, and having a ribbed adjustable connection end 266 for connection to a cross-panel member.

Embodiment 268 in FIG. 12 is a panel element having a smooth male connection end 262 and a smooth female connection end 264, but does not have a connection end for connection to a cross-panel member.

Connections between a smooth male connection end 262 and a smooth female connection end 264 are adjustable to allow very precise adjustments that do not require choosing one rib distance or another. The connections can be further locked in position, where desired, by glue, or screws, nails, or the like. In suitable applications, the connection can be left without glue, screws or nails or the like to allow for expansion or contraction.

With reference to FIGS. 13 and 14, embodiment 270 has a female adjustable connector 272 and a female adjustable connector 274, each of which have a female adjustable connector 278 and 280, and a fixed female connection end 30 and 32. Each of the female adjustable connection ends 278 and 280 are have relatively smooth surfaces to allow for micro adjustment and/or expansion and contraction of the joint. Double-ended male adjustable connector 276 at male adjustable connection ends 284 and 286 is configured to be inserted in female adjustable connection ends 278 and 280 respectively. Double-ended male adjustable connector 276 is similarly smooth, or relatively smooth, to allow for micro adjustments and/or expansion or contraction of the resulting joint formed with adjustable female connection ends.

The combination of the female adjustable connection ends 272 and 274 on connectors 278 and 280, when combined with double-ended male adjustable connector 276, is such that the spacing between female connector 278 and female connector 280 is adjustable depending upon how much of male connection ends 284 and 286 are inserted into female adjustable connection ends 278 and 280.

In FIG. 14, double-ended male adjustable connector 276 is inserted into female connection end 26 with two ribs of female connection ends 278 and 280 respectively. The lengths of the male adjustable connector 276 and the female adjustable connector ends 278 and 280 can be cut off on site, such as by using a knife and/or saw, to match the dimensions required so that a single seam with no gap can be achieved, while providing the correct spacing.

Embodiment 270, through fixed female connection ends 30 and 32, can be connected to known fixed-length modular formwork panels to add an adjustable length variation segment.

With reference to FIGS. 15 and 16, embodiment 290 has connector 292 with a fixed female end 30 and a click-in adjustable female connection end 296. Embodiment 290 further has a building element 294 having a click-in adjustable male connection end 298. Ash shown in FIG. 16, the click-in adjustable male connection end 298 can be pushed in direction 300 to click into adjustable female connection end 296 in a variety of positions, such as with one position not used, which can leave a gap 302. In other cases, gap 302 may be predetermined and may be filled with an insert, for example spacer insert 314 shown in FIG. 17.

Click-in adjustable male connection end 298 and click-in adjustable female connection end 296 are designed to push together in one direction and be locked from expanding apart. It may be possible to separate the two during construction by lifting one piece out of the other in a direction into or out of the plane of the paper in FIG. 16, a direction perpendicular to direction 300.

Embodiment 310 in FIG. 17 has double-ended click-in male adjustable connector 312 clicked into female adjustable connection end 296 of connector 292. Connector 312 is not fully inserted into connection end 296 due to the presence of spacer 314. The other end of connector 312 is fully inserted into adjustable female connection end 318 of connector 316, which also features fixed female connection end 320. In embodiment 310 there is a gap 322 between connectors 292 and 316 which in this case generally corresponds to the length of the spacer 314 to effectively lengthen the combination of connectors 292, 312 and 316. The gap 322 may be filled in by putty or plaster or a strip of PVC or metal or other suitable material, if desired, to create a uniform outward appearance for one or both surfaces.

Embodiments of this invention can be made from polyvinyl chloride (PVC), or from other suitable plastics, which depending upon the application may include ethylene propylene diene monomer (EPDM), thermoplastic elastomer polyolefin (TPO), cross-linked polyethylene (XLPE, marketed as PEX), polyethylene (PE), high-density polyethylene (HDPE), acrylonitrile butadiene styrene (ABS), nylon, ethylene vinyl acetate (EVA), poly(methyl methacrylate) (Plexiglass™), polypropylene (PP), polyolefins, and fiberglass. However, it is understood that it could be used with panels and connection systems using other suitable materials, such as cast aluminum, sheet metal, carbon fiber, or other suitable metals, synthetic or natural materials, including fiber cement, rubber, or wood. The invention has application for systems of mixed concrete forming and other materials, such as the use of Styrofoam™ or other forms of insulation replacing some or all of the concrete.

Some embodiments of the invention may have modular construction applications completely separate from concrete forming. For example, embodiments 224 and 260 could be used as a ceiling with connection ends 230 and 266, or suitable alternatives, used to secure the ceiling surface beams or other structure. Embodiments 224, 260 and 268, and similar, can be used as siding for buildings and/or for wall or flooring coverings and/or surfaces.

As will be apparent to those skilled in the art in the light of the foregoing disclosure the present invention is not limited by what has been particularly shown and described herein. Rather the scope of the present invention includes both combinations and sub-combinations of the features described hereinabove as well as modifications and variations thereof which would occur to a person of skill in the art upon reading the foregoing description and which are not in the prior art. Furthermore, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. For example, the illustrated embodiments show variable connections that are smooth, or having click-in surface contours, or having alternating perpendicular ribs and gaps, however it is to be understood that any reasonable variable connection is intended to be included within the scope of the invention, including dovetails, rounded protrusions and other suitable variations. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims. 

What is claimed is:
 1. An apparatus comprising: a first component having a first female adjustable connection end; and a second component having a first male adjustable connection end, said male adjustable connection end lockably insertable into said female adjustable connection in a plurality of positions to vary a length of a coupled combination of said first and second components.
 2. An apparatus as in claim 1, further comprising a plurality of wall forming panels coupled to said first and second components to form a wall having an inside wall surface and an outside wall surface, and reinforcing panels coupled to said inside wall surface and said outside wall surface.
 3. An apparatus as in claim 2, further comprising bracing panels coupled between said reinforcing panels and said inside or outside wall surface at 45 degree angles.
 4. An apparatus as in claim 3, wherein said first and second panels comprise plastic.
 5. An apparatus as in claim 4, said first female adjustable connection having 3-8 ribs on each side, each of said ribs separated by a corresponding gap.
 6. An apparatus as in claim 5, wherein said wall comprises a straight portion of wall.
 7. An apparatus as in claim 5, wherein said wall is a cylindrical wall.
 8. An apparatus as in claim 6, said wall comprising a concrete wall, said first and second components being concrete forming elements, said wall forming panels being concrete forming panels.
 9. An apparatus as in claim 7, said wall comprising a concrete wall, said first and second components being concrete forming elements, said wall forming panels being concrete forming panels.
 10. An apparatus as in claim 8, wherein each concrete forming panel is coupled via adjustable connection.
 11. An apparatus as in claim 9, wherein each concrete forming panel is coupled via adjustable connection.
 12. A method of building a structure comprising: inserting a first male adjustable connection end of a first building component into a first female adjustable connection end of a second building component wherein said first male and female adjustable connection ends are adjustable with respect to each other to lockably adjust a distance that said first male adjustable connection end is inserted into said first female adjustable connection end to effectively adjust a length of a coupled combination of said first and second building components.
 13. The method of claim 12 further comprising coupling said first and second building components to a plurality of wall forming panels to form a wall having an inside wall surface and an outside wall surface; coupling reinforcing panels to said inside wall surface and to said outside wall surface.
 14. The method of claim 13 further comprising coupling a bracing panel between said recinforcing panels and said inside wall surface at a 45 degree angle.
 15. The method of claim 14 wherein forming said wall comprises forming a straight portion of wall.
 16. The method of claim 14 wherein forming said wall comprises forming a cylindrical wall.
 17. The method of claim 15 further comprising inserting re-bar into cavities between said inside wall surface and said outside wall surface, and inserting re-bar through apertures in said reinforcing panels.
 18. The method of claim 17 further comprising pouring concrete into cavities between said inside wall surface and said outside wall surface, and through apertures in said reinforcing panels.
 19. The method of claim 18 further comprising smoothing said outside wall surface by attaching a seam filling segment to fill in an indentation gap from ribs of said first male adjustable connection end sticking out of said female adjustable connection end.
 20. An apparatus for forming a concrete wall comprising: a first concrete forming element having a first female adjustable connection end; and a second concrete forming element having a first male adjustable connection end, said male adjustable connection end lockably insertable into said female adjustable connection in a plurality of positions to vary a length of a coupled combination of said first and second concrete forming elements; a plurality of concrete forming panels coupled to said first and second concrete forming elements via adjustable connection to form a wall structure having an inside wall surface and an outside wall surface; reinforcing panels coupled to said inside wall surface and said outside wall surface; bracing panels coupled between said reinforcing panels and said inside or outside wall surface at 45 degree angles; said first and second concrete forming elements comprising plastic; said first female adjustable connection having 3-8 ribs on each side, each of said ribs separated by a corresponding gap; and said wall structure comprising a straight portion of wall. 